Infrared-emitting ceramics for fuel activation

ABSTRACT

This invention relates to a ceramic composite that comprises of a mixture of infrared-emitting metal oxides having specific spectral luminance in 3-20 μm (micrometers) wavelength range and an effective amount of pyroelectric material that helps enhance infrared emissions of said oxides in said wavelength range. Said ceramic composite can be deviced to provide an effective means of improving hydrocarbon fuel efficiency in internal combustion engines for better engine performance with increased torque and power, improved fuel economy, and reduced exhaust emissions. Such ceramic composites can also be used in other applications that utilize infrared emissions in said wavelength range.

BACKGROUND

1. Field of Invention

This invention relates to a ceramic composite, comprising a mixture ofinfrared-emitting oxides having specific spectral luminance in 3-20micrometers wavelength range and an effective amount of pyroelectricmaterial that helps enhance infrared emissions of said oxides in saidwavelength range, that provides an effective means of improvinghydrocarbon fuel efficiency in internal combustion engines for betterengine performance with increased torque and power, improved fueleconomy, and reduced exhaust emissions. Such ceramics can also be usedin other applications that utilize infrared emissions in said wavelengthrange.

2. Description of Prior Art

According to Organic Chemistry photoexciting hydrocarbons with infraredphotons shorter than 20 μm (micrometers) in wavelengths for improvingfuel conversion efficiency is scientifically possible and has beenproven by the present inventor in laboratory studies.

After years of research the present inventor discovered the use ofinfrared radiation at 3-14 μm wavelengths, defined as “mid-infrared” byU.S. NASA but “far infrared” in Japanese convention, for enhancingcombustion efficiency of hydrocarbon fuel in internal combustion enginesand resulted in the inventions of fuel combustion enhancement devices asdisclosed in U.S. Pat. Nos. 6,026,788, 6,082,339 and 7,617,815.

These inventions are based on known science. It is recognized in OrganicChemistry that hydrocarbons are infrared-active and absorb multiphotonsin 3-20 μm wavelengths causing molecular vibrations. In Photochemistry,enhancement of reaction rates by reactant vibrational excitation hadbeen demonstrated in laboratory dynamics studies. The present inventorhas proven the underlining science of infrared-fuel effect in a laminarnon-premixed counterflow methane-air flame experimentation to helppinpoint the IR-excitation influences on combustion of hydrocarbonfuels. The present inventor further verified in engine tests thatincreasing infrared exposure in said wavelengths results in betterengine performance.

Though the device as described in the U.S. Pat. Nos. 6,026,788 and7,617,815 by the present inventor worked adequately for both light dutygasoline and diesel engines, the fuel activation effect became limitedin the applications with heavy duty diesel engines, such as in tractors,earth moving equipment, marine vessels, locomotives, or powergenerators. These applications require irradiating an extensive flow offuel substance in a very short time interval. It is because of the factthat only a small portion of the fuel substance is used in combustionfor generating power, while the majority is utilized as lubricant andcoolant in the turbo-pump system for fuel injection. Therefore, aninnovative ceramic material with significantly amplified infraredemissions would be required for such applications.

Accordingly, the present inventor started searching issued patents andpublications in this field for ideas, including U.S. Pat. Nos.7,021,297, 7,036,492, 7,281,526, and 7,406,956, just to name a few.However, the present inventor found that the prior art failed toexpressly or implicatively teach the way of making such aninfrared-emitting ceramic with amplified luminance in said wavelengthrange. Therefore, the present inventor had to launch his own researchand came up with the present invention.

After three years of intensive research, the present inventorsuccessfully developed a ceramic composite that requires mixing varioustransition metal oxides, such as zirconia, titanium oxides, cobaltoxides, and others, as disclosed in U.S. Pat. Nos. 6,026,788 and7,617,815 by the present inventor, with an effective amount ofpyroelectric material in order to amplify the characteristic spectralluminance of the resultant ceramic composite. The processes also involvemixing, grinding, adding catalyst to the solution, dehydrating, greenstate forming, settling, pressing, molding, sintering, and roomtemperature resting.

Transition metal oxides with electrons occupying outer orbits [nd]¹⁻⁹[(n+1)s]⁰⁻² have such a unique property that the electrons can bethermally agitated to vibrate, moving between “bonding” (donation ofelectrons from transition metals) and “back-bonding” (back-donation ofelectrons to transition metals). The difference in energy levels isabout 0.1-0.3 eV, which corresponds to photon emissions in 3-20 μmwavelengths as governed by the following formula: E (eV)=1.2398/λ (μm).

On the other hand, pyroelectric materials have an ability to generate atemporary electrical potential when they are heated or cooled. Thechange in temperature can slightly modify the positions of atoms withinthe crystal structure so that the polarization of the material maychange. The polarization change gives rise to a temporary potential,although this disappears after the dielectric relaxation time.Nevertheless, this slight polarization change in crystal structureenables the orbital electrons in said transition metal oxides to jumpbetween orbits more easily and frequently. Thus, adding pyroelectricmaterial to the mixture of infrared-emitting oxides helps the resultantceramic composite capture ambient temperature change and use it tosignificantly improve infrared emissions.

According to the present inventor's study, there are ten polar crystalstructures that posses a temperature-dependent spontaneous polarizationand exhibit pyroelectricity, which are sometimes referred as thepyroelectric classes. These crystal structures are 1, 2, m, mm2, 3, 3m,4, 4 mm, 6, 6 mm, by their International Hermann-Mauquin notation.

The present inventor has developed prototype ceramic composites bypurposely adding various amount of pyroelectric material, about 5-40% byweight, to a mixture of selected infrared-emitting metal oxides. Thecomposite was then sintered at a temperature above 1200° C. The presentinventor further discovered experimentally that adding an optimal amountof about 15-25% pyroelectric material would significantly increase thefuel activation effect and thus dramatically improve engine performance.

As described above, the prior art failed to teach the use of a mixtureof selected infrared-emitting metal oxides having a specific spectralluminance in 3-20 μm wavelengths and an effective amount of pyroelectricmaterial for boosting infrared emissions in said wavelength range andthus maximizing hydrocarbon fuel combustion efficiency in engines.

OBJECTS AND ADVANTAGES

Accordingly, one object of this invention is to provide a ceramiccomposite that has amplified infrared emissions in 3-20 μm wavelengthrange;

Another object of the present invention is to provide a device foreffectively increasing combustion efficiency of hydrocarbon fuel ininternal combustion engine to enhance its performance for increasedpower, improved fuel economy, and reduced tailpipe emissions;

Also, an object of the present invention is to provide a simple,easy-to-use, and maintenance-free fuel combustion efficiency enhancementdevice.

These objectives are achieved by a device based on a ceramic compositecomprising essentially a mixture of selected infrared-emitting metaloxides and an effective amount of pyrpelectric material. The ceramiccomposite can be disposed either on exterior or in interior of anaccessory of the fuel systems of an engine so that the hydrocarbon fuelflowing through said accessory may be excited by infrared from saidcomposite for improved combustion efficiency. Said accessory may be fueltank, pump, line, filter, injector, and the like.

Other objects, features, and advantages of the present invention willhereinafter become apparent to those skilled in the art from thefollowing description.

DRAWING FIGURES

FIG. 1 shows a perspective view of one embodiment of the presentinvention with the ceramic composites in partial-tubular form beingmounted on a fuel line.

FIG. 2 shows a perspective view of another embodiment of the presentinvention with the ceramic composites being disposed on the exterior ofa fuel line connecting to an accessory of the fuel systems of an engine.

FIG. 3 shows a perspective view of another embodiment of the presentinvention with the ceramic composites being disposed in the interior ofan accessory of the fuel systems of an engine, which may be fuel tanks,pumps, lines, filters, injectors, or the like.

REFERENCE NUMERALS IN DRAWINGS

11 Infrared-emitting ceramic composite 21 Fuel line 22 Accessory ofEngine Fuel systems 31 Attachment means

Summary

In accordance with the present invention a ceramic composite comprisesof a mixture of infrared-emitting metal oxides having specific spectralluminance in 3-20 μm wavelength range and an effective amount ofpyroelectric material that helps enhance infrared emissions of saidoxides in said wavelength range. Said ceramic composite provides aneffective means of improving hydrocarbon fuel efficiency in internalcombustion engines for better engine performance with increased torqueand power, improved fuel economy, and reduced exhaust emissions. Suchceramic composites can also be used in other applications that utilizeinfrared emissions in said wavelength range.

DETAILED DESCRIPTION OF THE INVENTION

The present inventor had invented the fuel activation devices (U.S. Pat.Nos. 6,026,788, 6,082,339 & 7,617,815) using infrared emissions in 3-14μm wavelength range to excite hydrocarbon fuels and reported favorableresults on improving engine performance with such devices. Moreover,since some applications with heavy-duty diesel engines require massiveinfrared exposure to the fuel, the present inventor experimentally foundthat adding an effective amount of pyroelectric material to theinfrared-emitting metal oxides composition that was disclosed inaforementioned patents would significantly increase the infraredemissions for the purposed applications.

As stated before, there are ten polar crystal structures that posses atemperature-dependent spontaneous polarization and exhibitpyroelectricity. These crystals are referred as the pyroelectricclasses, which include 1, 2, m, mm2, 3, 3m, 4, 4 mm, 6, 6 mm, by theirInternational Hermann-Mauquin notation. They are, but not limited to,Halotrichite (2), Jarosite (3), and Alunite (3m) from complex sulfatesystem; Hemimorphite (mm2), Bertrandite (mm2), Schorl (3m), Cerite (3m),and Cancrinite (6) from silicate system; and Nepheline (6) from silicasystem. Their International Hermann-Mauquin notation is provided inparenthesis. It is worthwhile noting hereby that Schorl (3m) is the mostcommon species of tourmaline and may account for 95% of all tourmalinein nature.

The ceramic composite of the present invention can be engineered asfollows: First, prepare a mixture of powders of infrared-emitting metaloxides selected from the oxide groups as disclosed in the U.S. Pat. Nos.6,026,788 and 7,617,815 by the present inventor in theoreticalpercentages by weight for the intended peak wavelengths and spectralluminance. Then, add an effective amount of pyroelectric material to theoxides mixture. The pyroelectric material may be about 5-40% by weight,while 15-25% would lead to optimal results. Lastly, the mixture of metaloxides and pyroelectric material, along with bonding agent, catalysts,and stabilizers, will be press-molded to the desired shapes and sinteredin a furnace at a preferred temperature 1200° C. or above. Severalexamples of the present invention were prepared accordingly forconcept-demonstrating experiments.

FIG. 1 shows a perspective view of a simple embodiment of the presentinvention, in which two pieces of infrared-emitting ceramic composites,11, are mounted on a nonmetal fuel line, 21, of an engine. The twoceramic pieces may be secured to the fuel line with an attachment means,31. In this case, it is simply a wrap tie. The ceramics of presentinvention can take any shapes, forms, styles, patterns, and in anythickness, though a partial-tubular shape is preferred for the ease ofcontouring to the fuel line. FIGS. 2 and 3 show a perspective view ofanother embodiment of the present invention that incorporates theceramics as a part of an accessory in the fuel systems of engine. FIG. 2shows the ceramics being mounted on the exterior of the fuel line thatconnects to said accessory. In contrast, FIG. 3 shows the ceramics beingdisposed inside the accessory, in direct contact with fuel. Saidaccessory of the fuel systems may be fuel tanks, pumps, lines, filters,injectors, or the like, that form the fuel path from fuel tank to engineand return. In other embodiments, the infrared emitting ceramics can bedisposed in the interior of said accessory, embedded or coated on theinner wall, or being a part of said accessory.

The ceramics of the present invention can also be used in applicationsthat use infrared in 3-20 μm wavelength range, such as therapeuticapplications or water and drinks treatment.

EXAMPLES

Several ceramic samples of the present invention were designed anddevised, specifically for demonstration in heavy-duty diesel engineapplications. The samples contain, by weight, 20% silicate, 20% alumina,24% zirconia, 4% sodium monoxide, 3% potassium oxide, 3% ferric oxide,5% chromic oxide, 4% cobalt oxide, 2% all other minority oxides, and 15%pyroelectric material. Different samples that varied in weightpercentages of the aforementioned ingredients were also made to tailorthe specific spectral luminance.

Beta-Site Marine Diesel Engine Testing

The ceramic samples were tested by Motore MTU Italia s.r.l. (La Spezia,Italy) on its 8V4000M63 Model diesel engine in marine applications(rated max. power: 1000 kW@1800 RPM). Motore MTU's state-of-the-arttesting facilities provide accurate and reliable measurement. Duringtesting, CO₂ concentration in engine exhaust emissions was used as anindicator of fuel consumption, as it is nearly linearly proportional tothe amount of fuel consumed in engine operation. To demonstrate theinfrared-excitation effect on improvement of fuel economy, two fuelpaths were implemented, one being regular fuel line as a “Baseline”configuration and the other having infrared-emitting ceramicssurrounding the fuel hose as an “IR-excited” configuration. These twofuel lines were connected in parallel, with controlled valves at bothends. One end was connected to supply fuel line, while the other end toengine common rail for fuel injection. The valves could be switchedinstantly for selecting the fuel path between “Baseline” and“IR-excited”. The engine was set to run at a constant speed of 1000 RPMand under a constant load at 1740 Newton torque. When the “Baseline”fuel path was selected, the CO₂ concentration was measured to be 5.4%.After it was switched to be “IR-excited”, the CO₂ concentration wasmeasured to be 4.8%, which indicates an about 12% drop in CO₂concentration. It means that the ceramics of the present invention helpreduce fuel consumption by about 12% for said engine operation.

CONCLUSION, RAMIFICATIONS, AND SCOPE

According to the present invention, a ceramic composite with amplifiedinfrared-emissions comprises of a mixture of infrared-emitting metaloxides having specific spectral luminance in 3-20 μm wavelength rangeand an effective amount of pyroelectric material that helps enhanceinfrared emissions of said oxides in said wavelength range. Said ceramiccomposites can be devised to provide an effective means of improvinghydrocarbon fuel efficiency in internal combustion engines for betterengine performance with increased torque and power, improved fueleconomy, and reduced exhaust emissions.

The invention has been described above. Obviously, numerousmodifications and variations of the present invention are possible inlight of the above teachings. Such variations are not to be regarded asa departure from the spirit and scope of the invention and all suchmodifications as would be obvious to one skilled in the art are intendedto be included within the scope of the following claims.

1. A fuel activation device for exciting hydrocarbon fuel of an internalcombustion engine and for thereby achieving efficient combustion of thefuel in the engine, said device consisting of essentially at least aninfrared emitting ceramic composite disposed in the fuel systems of theengine whereby fuel used for the engine passes through, said ceramiccomposite comprising of a mixture of infrared-emitting metal oxideshaving specific spectral luminance in 3-20 micrometers wavelength rangeand an effective amount of pyroelectric material.
 2. A device accordingto claim 1 wherein pyroelectric material is 5-40% by weight.
 3. A deviceaccording to claim 1 wherein said ceramic composite is mounted on theexterior of a nonmetal fuel line of the engine.
 4. A device according toclaim 1 wherein said ceramic composite is disposed on the inside of anaccessory in the fuel systems, said accessory being fuel tank, pump,line, filter, injector, and the like.
 5. A ceramic composite forproviding amplified infrared luminance in 3-20 micrometers wavelengthrange, said ceramic composite comprising of a mixture ofinfrared-emitting metal oxides having specific spectral luminance insaid wavelength range and a pyroelectric material, said pyroelectricmaterial being about 5-40% by weight.
 6. A method for producing aceramic composite with amplified infrared luminance in 3-20 micrometerswavelength range, said method comprising mixing powders of infraredemitting metal oxides that have specific spectral luminance in saidwavelength range with powders of pyroelectric material, saidpyroelectric material being about 5-40% by weight.